Owner`s/Operator`s Manual - Yamaha Golf-Car
Contents
1. ATION fuel lines for leakage c c c c c CHECKS Check fuel level c c c c c Check for looseness and corrosion of battery c c c c c terminals and hold downs Check brake pedal freeplay and adjust if necessary Check steering operation c Check tire pressure tread depth tire surface for damage Check body and chassis for damage Check tightness of all bolts nuts and screws CA CA CA Check reverse buzzer operation Check fuel filter for clogging Check wear of drive belt Check operation of Forward Reverse shifting Clean Lube pedal control area EVERY 6 Wash pre filter check air MONTHS cleaner element Check spark plug and plug cap condition Check compression Check shock absorbers for oil leaks and damaged springs Items with out a page number reference should be serviced by a Yamaha dealer or other qualified mechanic This manual does not contain these procedures They are contained in the Service Manual Related to emission control system 8 1 G22A FOR G22A C CHECK AND ADJUST R REPLACE S SERVICE CL CLEAN AND LUBRICATE L LUBRICATE 20 Rounds 125 rds 250 rds 500 rds 1000 rds 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs Remarks 100 miles 600 mis 1200 mis 2500 mis 5000mis 160 kms 1000 kms 2000 kms 4000 kms 8000 kms Every Every 6 Every Every Every month months year 22. adjusting Before you operate the car press down on the brake pedal several times to make sure the brakes are functioning properly 4 WARNING Consult your Yamaha dealer before using your golf car if you suspect brake problems Brake failure could result in a serious accident G22A MAINTENANCE G22A Brake Pedal Free Play Adjustment CAUTION Before adjusting brake pedal free play pump the brake pedal several times to self adjust the brakes To adjust the brake pedal free play 1 Remove the service lid from the floor of the golf car 2 Check the brake pedal free play by pressing against the pedal with two fingers using light force and measuring the distance the pedal travels before resistance is felt Brake pedal free play 20 25 mm 0 79 0 98 in 3 If the free play distance needs adjusting loosen the lock nut and turn the adjusting nut in or out until the free play specification is met Then tighten the lock nut in place A WARNING Do not overtighten the brake cables The self adjusters may not operate properly reducing braking performance 8 12 STORAGE Perform the following preparations when storing your golf car for extend ed periods of time NOTE Turn main switch key to OFF posi tion remove key and store key in a safe place DRAINING FUEL Gasoline and its vapors are highly flammable and explosive e
3. Electronic Ignition PLUG SPARK e CRANKCASE 1 8 HEAD PCV Positive Crankcase CYLINDER 1 Ventilation AIR FILTER ASSY ACL Air Cleaner MUFF 2 p The above items and the correspond ing acronyms are provided in accor dance with U S EPA REGULATIONS FOR SMALL NONROAD ENGINES and the CALIFORNIA REGULA TIONS FOR NEW 1995 AND LATER OFF HIGHWAY RECREATIONAL VEHICLES AND ENGINES The acronyms conform to the latest version of the SAE s recommended practice document J1930 Diagnostic Acronyms Terms and Definitions For Electrical Electronic System It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic 8 3 G22A MAINTENANCE G22A Spark Plug Inspection You should periodically remove and inspect the spark plug Dirty or worn spark plugs can cause poor perfor mance Spark plug Spark plug cap 1 Check for discoloration and remove carbon deposits with a spark plug cleaner or wire brush The normal electrode color will be tan 2 Check the spark plug type and check the spark plug gap with a feeler gauge Standard spark plug BPR2ES Spark plug gap 0 028 0 031 in 0 7 0 8 mm Gap 3 Clean the gasket and plug sur faces and install the spark plug finger tight before tightening to the following torque Spark plug torque 14 5 ft lb 20 Nm 2 0 m kg WARNING When removing installing the spark plug be
4. Engine oil capacity 1 16 US qt 1 1 L 1100 cc Oil change quantity 1 0 US qt 0 9 L 900 cc 6 3 ENGINE OIL With the golf car parked on level ground remove the dipstick and make sure the engine oil is between the MIN and MAX marks the cross hatched area on the end of the dip stick Oil level dipstick Maximum oil level Safe operating range If the oil level is below the MIN mark on the dipstick add oil through the oil filler hole until the oil level is between the MIN and MAX marks Oil filler hole CAUTION e Use care not to fill past the MAX dipstick mark and be sure no foreign material enters the crankcase e Use care not to get oil on the starter belt NOTE nn The distance between the dipstick marks represents approx 1 2 US qt 1 2 L of oil NOTE Recommended engine oil classifica tion API Service SE SF or SG Engine oils labeled Energy Con serving II are recommended G22A PRE OPERATION CHECKS Engine Cooling Inlet Duct Check the engine cooling inlet duct for debris Remove any debris present Engine cooling inlet duct BATTERY Check that the battery is held secure ly in place to prevent the battery from being damaged from vibration or jar ring Also check that no battery caps are missing to prevent battery acid from spilling from the battery Check the battery terminals for corrosion TIRE CONDITION
5. 6 Tire Air Pressure Check the tire air pressure before operating the golf car Tire pressure For G22A 16 psi 110 kPa 1 1 kgf cm Tire Wear Limit Check the surface for damage cracks or embedded objects When tire tread wears down to 0 04 in 1 mm replace the tire Wear limit G22A 6 4 PRE OPERATION CHECKS 6 5 STEERING SYSTEM Check the steering system for exces sive freeplay by e moving the steering wheel up and down and back and forth e turning the steering wheel slightly to the right and left If you feel excessive freeplay or hear rattling sounds which may indicate loose steering components consult a Yamaha dealer BACK UP BUZZER Check the back up buzzer by moving the drive select lever to R for reverse The buzzer should sound PEDAL OPERATION Check the following pedal controls for proper operation If a pedal does not work properly consult a Yamaha dealer Brake Pedal Make sure the brake pedal feels firm when pressed and returns to its orig inal position when released Brake pedal G22A PRE OPERATION CHECKS Parking Brake Pedal Make sure the parking brake pedal locks in place with a positive click and releases when the accelerator pedal is pressed Parking brake pedal NOTE Release the parking brake by depressing the accelerator pedal Accelerator Pedal PW abb Before checking operation of the acceler
6. Do not smoke when draining fuel and keep away from sparks flames or other sources of igni tion e Stop engine and allow it to cool for several minutes before drain ing fuel e Drain fuel in a well ventilated area e Take care not to spill gasoline If gasoline spills wipe it up imme diately with dry rags Always dis pose of gasoline soaked rags properly e Tighten the filler cap securely after checking fuel level e If you inhale a lot of gasoline vapor or get gasoline in your eyes get immediate medical attention e If any gasoline gets on your skin immediately wash with soap and water Change clothing if gaso line spills on it 1 Fill the fuel tank Float bowl drain screw 2 Drain the carburetor float bowl into a suitable container by turning the screw located on the bottom of the carburetor G22A STORAGE ENGINE PREPARATION With the key removed and the spark plug lead disconnected turn the clutch by hand until compression is felt This puts the valves in the closed position CHASSIS PREPARATION 1 Increase the tire pressure to 20 psi 137 kPa 1 4 kgf cm2 2 Clean exterior of the golf car and apply a rust inhibitor 3 Cover the golf car with a breath able cover and store it in a dry well ventilated area BATTERY PREPARATION 1 Remove the battery from the golf car and store it in a cool dry place that stays between 32 F 0 and 90 F 30 C G22A 2 Have t
7. You do not have to remove the cover 2 Pull cap off fuse Pull fuse out and replace if necessary Fuse cap D Fuse Replacement Fuse 10 Amp Blade Style G22A MAINTENANCE Gear Box Oil To check gear box oil level 1 Place the golf car on a level sur face 2 Remove the access panel by removing the screws in the two lower corners of the panel and pulling the panel from the car 3 Remove the oil level plug 4 Add gear oil little by little until oil flows from the level plug hole 5 Allow excess gear oil to flow out until it stops CAUTION Do not allow foreign material to enter the gear box Recommended oil T SAE AGF 6 Reinstall the oil level plug Gearcase capacity G22A 0 44 US qt NOTE NN gt 415 mL 415 For gear oil replacement consult a Yamaha dealer or other qualified mechanic G22A 8 10 MAINTENANCE 8 11 CAUTION Before performing wheel or brake maintenance verify that the main switch is in the OFF position Wheel Replacement remove and install a wheel on your golf car 1 With the wheels blocked to pre vent the golf car from moving loosen the wheel nuts 2 Elevate the golf car with a jack and remove the wheel nuts and the wheel 3 Reverse the removal steps when installing the wheel Wheel nut tightening torque 58 ft lb 80 Nm 8 0 m kg Brake Adjustment The brakes on your golf car are self
8. careful not to dam age the insulator A damaged insu lator could allow external sparks which could lead to explosion or fire 8 4 MAINTENANCE Recommended oil YAMALUBE 4 cycle oil or SAE 10W 30 Engine oil capacity 1 16 US qt 1 1 L 1100 cc Oil change quantity 1 0 US qt 0 9 L 900 cc 8 5 Engine Oil Replacement 1 Warm up the engine for several minutes place the golf car on a level surface then stop the engine WARNING Use caution not to touch hot engine oil or hot engine parts dur ing the following procedure 2 Place an oil pan under the engine drain plug 3 Remove the oil drain plug and let the oil drain completely NOTE Dispose of used oil in an environmen tally safe way such as taking oil to an oil collection station 4 Install the drain plug along with a new drain plug gasket finger tight before tightening to the following torque Drain plug torque 23 ft lb 31 Nm 3 1 m kg 5 Add the correct quantity of oil through the oil filler hole NOTE o Recommended engine oil classifica tion API Service SE SF or SG Engine oils labeled Energy Con serving II are recommended G22A MAINTENANCE G22A Oil filler hole CAUTION Use care not to fill past the MAX dipstick mark and be sure no for eign material enters the crank case After replacing engine oil check for oil leaks around t
9. carrier scorecard holder and the trim Parts excluded from the third year of war ranty include the second year exclusions the electrical system except electronic speed controller and electric motor and control cables Other specific exclusions from this warranty shall include any parts replaced due to normal wear or routine maintenance including oil air filter elements brake shoes spark plugs starter and clutch drive belts Any charges incurred in transporting a golf car to and from an authorized Yamaha Golf Car Dealer for service or in performing field service are also excluded from this warranty 1 1 THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the golf car as specified in the appropriate Owner s Operator s Manual 2 Give notice to an authorized Yamaha dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs by the dealer s autho rized representative WARRANTY TRANSFER To transfer any remaining warranty from the original purchaser to any subsequent purchaser it is imperative that the machine be inspect ed and registered for warranty by an authorized Yamaha Golf Car Dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service YAMAHA M
10. years 4 years Replace engine oil R R R Adjust throttle cables choke cable check carburetor CA CA throttle shaft for wear Check starter V belt for damage and tension Check drive belt for slippage wear or scratches Check sliding sheave and ramp shoes Grease secondary sheave bearing Grease primary sheave Check operation of speed limiter Apply battery terminal protectant Check wiring connections and insulation Check shoe lining thickness and rear axle bearing play Check steering knuckle bushing freeplay Adjust wheel alignment Check wheel nut tightness front wheel bearing play Check gear box oil level and leakage Check operation and adjust pedal stop if necessary Check brushes for wear and commutator for dirt Replace fuel filter and fuel hoses Check tightness of cylinder head Adjust valves Replace gear box oil Check for grease leakage adjust gearbox if necessary Items with out a page number reference should be serviced by a Yamaha dealer or other qualified mechanic This manual does not contain these procedures They are contained in the Service Manual Related to emission control system G22A 8 2 MAINTENANCE EXHAUST EMISSION CONTROL SYSTEM AND COMPONENTS e CARB ASSY LH JT CARB Carburetor CARBURETOR 2 amp JT CARBURETOR 1 MAGNETO ASSY 8 EI
11. 0 mm Replace when belt reaches 1 06 in 27 mm 5 To install the drive belt reverse the above steps rolling the belt back over the secondary sheave Battery Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or veg etable oil Call physician immedi ately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHIL DREN 8 8 MAINTENANCE The 12 volt battery that provides start ing power to your gas car normally doesn t require the addition of water during the one year period provided by the battery manufacturer If the bat tery loses its charge have an experi enced mechanic charge it Fuse Replacement 4 WARNING sure to use specified fuse Using a wrong fuse can cause elec trical system damage and create a fire hazard CAUTION When replacing a fuse be sure the main switch is turned off to prevent accidental short circuiting 1 Remove cap screw on cover Pull fuse case cover forward Cap screw Fuse case cover NOTE nm
12. 18 x 8 50 8 00 4 PR 7 00 1 8 00 For G16A 16 psi 110 kPa 1 1 kgf cm G22A WIRING G22A WIRING DIAGRAM 60S A pog JojeJeue Jej18 S Jezzng G 2 u yams yoeg vot epejq dois E a 9 U2IIMS Urey 10104 ma dwel 9 dn xolg 6 9 Kejeg dois 1 18 as D 06 eiu peu We MOJ SA PSH NH HOBJA MOJISA aA peuppelg SHUM 77 M uMOJg Jg H MOJJSA UA UU elal s ety 1 4009 40109 o a U gt 11 1 G22A NOTES NOTES NOTES Printed in U S A 2004 KCC MANUFACTURING CORP OF AMERICA 1000 HWY 34 East Newnan GA 30265 770 254 4000
13. OTOR MANUFACTURING CORPORA TION OF AMERICA MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULIAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIM ITS STATED IN THIS WARRANTY ARE HEREBY DIS CLAIMED BY YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCI DENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR MANUFACTURING CORP NEWNAN GEORGIA 30265 1320 EFFECTIVE DATE 06 01 02 LIT 13710 03 02 G22A IMPORTANT LABELS ZN SAFETY AND INSTRUCTION LABELS 4 WARNING Please read the following labels carefully before operating your golf car and promptly replace any labels which become dam aged or removed OPERATING INSTRUCTIONS Read the warning label on the beverage holder panel before operating Be sure occupants are seated Select FORWARD or REVERSE then turn main switch to ON Press the accelerator pedal to start moving The motor will start and the parking
14. YAMAHA OVVNER S OPERATOR S MANUAL GOLF CAR cza LIT 19626 16 04 JU0 F8199 12 The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 G22A INTRODUCTION Congratulations on your purchase of Yamaha golf car This manual contains information you will need for proper operation maintenance and care of your golf car A thorough understanding of these simple instructions will help you to obtain maximum enjoyment from your new Yamaha If you have any questions about the operation or maintenance of your golf car please consult a Yamaha dealer YAMAHA MOTOR MANUFACTURING CORP OF AMERICA G22A OWNER S OPERATOR S MANUAL 2004 by Yamaha Motor Manufacturing Corporation of America 1st edition AII rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Manufacturing Corporation of America is expressly prohibited Printed in U S A P N LIT 19626 16 04 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BE ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instruc tions could result in severe injury or death to the golf car occupants a bystander or a person inspecting or repai
15. ator pedal be sure the main switch is in the OFF posi tion Make sure the accelerator pedal operates smoothly Accelerator pedal BODY AND CHASSIS Before each use visually inspect the golf car body and chassis for damage and or missing parts G22A 6 6 OPERATION 7 1 STARTING 1 With the parking brake applied turn the drive select lever to for forward or for reverse CAUTION Do not shift from forward to reverse while the golf car is moving 2 Turn the main switch to 4 WARNING Do not depress the accelerator pedal when turning on the main switch or the golf car may sudden ly start moving e Pull the choke knob out and hold it while starting Release the choke knob after the engine starts Choke knob NOTE The choke is not required when the engine is warm 4 Check that your path is clear in the direction you plan to go and slowly depress the accelerator pedal The golf car will start to move Accelerator pedal NOTE LL The parking brake automatically releases when the accelerator pedal is depressed G22A OPERATION TROUBLESHOOTING If the vehicle s engine won t start use the following chart Cause Fuel System No fuel in tank Fill fuel tank Clogged fuel Clean fuel line line Consult Yamaha dealer Clean fuel Consult Yamaha deale
16. brake will release automatically To stop release the accelerator pedal and press the brake pedal NAE Never travel ot speeds too fast for the terrain visibility WARNING AVERTISSEMENT Ne pas toucher au r gulateur afin d augmenter la Parkint Broke edal Accelerator Pedal Do not tamper with governor YAMAHA conditions or your experience Drive with extra caution in congested areas when operating in reverse and when driving on wet rough or loose surfaces Come to a complete stop before reversing direction Press the parking brake pedal until it locks and turn the main switch to OFF before leaving the vehicle Read the Owner s Operator s Manual for more information ATTENTION This vehicle was not manufactured for use on public streets and does not comply with federal motor vehicle safety standards opplicable to passenger cars Y 500 JUO K7762 00 to increase speed Operation at higher speeds can cause loss of control that can result in severe injury or death vitesse Un fonctionnement a des vitesses sup rieures au r glage initial peut causer une perte de contr le qui peut mener a une blessure grave voire fatale JN3 K8299 10 WARNING DEATH OR SEVERE PERSONAL INJURY CAN RESULT FROM FAILURE TO FOLLOW THESE INSTRUCTIONS Read Operating Instructions on steering wheel Operate from driver s side only before operation Do not allow more than two occupants in vehicle Opera
17. check the following Fuel system Engine oil level Battery w Tire condition w Steering system V Back up buzzer Pedal operation w Body and chassis SEAT Open the seat for checking and ser vicing 6 1 G22A PRE OPERATION CHECKS Recommended fuel Unleaded gasoline Fuel tank capacity 6 1 US gal 23 0 L G22A FUEL SYSTEM Make sure there is sufficient fuel in the tank and check fuel line and con nections for leakage Fuel tank Fuel cap 4 WARNING Gasoline and its vapors are highly flammable and explosive e Do not smoke when refueling and keep away from sparks flames or other sources of igni tion e Stop engine and allow it to cool for several minutes before refuel ing e Refuel in a well ventilated area e Take care not to spill gasoline If gasoline spills wipe it up imme diately with dry rags Always dis pose of gasoline soaked rags properly e Tighten the filler cap securely after refueling e If you swallow gasoline inhale a lot of gasoline vapor or get gasoline in your eyes get imme diate medical attention e If any gasoline gets on your skin immediately wash with soap and water Change clothing if gaso line spills on it CAUTION Avoid using gasoline blended with methyl alcohol which can damage fuel system parts 6 2 PRE OPERATION CHECKS MIN MAX Recommended oil YAMALUBE 4 cycle oil or SAE 10W 30
18. dition which affects capacity or safe operation or make any changes not in accordance with the owner s operator s manual G22A N GOLF COURSE SAFETY PROGRAM Like all machines golf cars can cause injury if improperly used or maintained This section contains broad safety practices required for safe golf car operation Before golf cars are operated golf course per sonnel should establish any addition al safety practices that may be required for safe operation Experience has shown that golf cars are safe when operated in accor dance with the safety warnings affixed to every golf car This safe operation is enhanced when golf cars are used according to the safety rules and practices established to meet the terrain and conditions of the course they are used on The information contained here is intended for golf course personnel responsible for golf car safety If you are responsible for the operation and maintenance of this golf car we encourage you to implement this golf car safety program DRIVER QUALIFICATIONS Allow only authorized people to oper ate golf cars It is recommended that only people who possess a valid motor vehicle driver s license be allowed to operate golf cars Place operation and safety instruc tions recommended by the golf car manufacturer along with the golf course safety rules in a conspicuous place near the golf car rental area or golf car pick up area It is also rec ommended tha
19. e desired posi tion Lever Position Car Movement FORWARD REVERSE NOTE The back up buzzer will beep when the drive select lever is turned to ACCELERATOR PEDAL The accelerator pedal controls the golf car s speed Action Car Speed Depress pedal Increase Release pedal Decrease Accelerator pedal BRAKE PEDAL Press down on the brake pedal to stop the golf car Brake pedal G22A CONTROLS G22A PARKING BRAKE PEDAL Press down on the parking brake pedal whenever parking the golf car Parking brake pedal NOTE Release the parking brake by depressing the accelerator pedal 4 WARNING The parking brake will automatically release when the accelerator pedal is depressed If the main switch is in the ON position depressing the accelerator may suddenly cause the golf car to move CHOKE KNOB Pull and hold out choke knob when starting a cold engine Release the knob after the engine starts Choke knob 5 4 PRE OPERATION CHECKS Pre operation checks should be made each time you use your golf Get in the habit of performing the following checks in the same way so that they become second nature A WARNING e Be sure the main switch key is removed before performing the pre operation checks to prevent accidental starting and apply the parking brake to keep the car from moving PRE OPERATION CHECKLIST Before each use
20. e worker safety e Supervise the storage and han dling of liquid fuels in accordance with applicable fire and safety requirements e Only use battery changing and charging facilities and procedures that are in accordance with applic able ordinances and regulations e Periodically inspect fueling and charging facilities and procedures to be certain that applicable safety codes regulations and procedures are being followed 4 3 CONTROLS FEATURES D Steering wheel 2 Seat 3 Fuel cap 4 Brake pedal 5 Parking brake pedal 6 Accelerator pedal 7 Drive selector lever Main switch Oil warning light Choke knob t Front cowl 62 Front tire 63 Front bumper Rear cowl i Rear bumper Rear tire 7 Battery 5 1 G22A CONTROLS MAIN SWITCH The main switch controls the follow ing items OFF Ignition circuit is switched off The key can be removed only in this position Electrical circuits are switched on The golf car can be driven OIL WARNING LIGHT When the engine oil level falls below an acceptable level this light comes on If the light comes on stop the engine check the engine oil level and add oil as necessary See page 6 3 Oil warning light G22A 5 2 CONTROLS DRIVE SELECT LEVER The drive select lever is used to shift the golf car into forward or reverse After coming to a complete stop move the lever to th
21. he drain plug If oil leaks are found consult a Yamaha dealer Air Filter To remove the air filter elements 1 Unlatch the air filter cover clips and remove cover Air filter cover clips Air filter cover 2 Lift the air filter and pre filter out of the air filter case Air filter Pre filter CAUTION Be careful not to drop anything into the air inlet 8 6 MAINTENANCE 8 7 Inspection and cleaning 3 Wash the foam pre filter in soap and water Allow it to dry Soap and water Foam element 4 Check the filter element If dam aged or dirty replace it CAUTION Do not wring out the foam pre fil ter this could cause it to tear 5 To replace the elements reverse the above steps CAUTION The pre filter has a notch on one side It will only fit in the case one way Drive Belt To remove the drive belt 1 Set the drive select lever halfway between forward and reverse 2 Pull up on the drive belt and push it outward over the edge of the secondary sheave 3 Turn the secondary sheave clock wise and the drive belt will roll off the sheave 4 Remove the drive belt from the primary sheave G22A MAINTENANCE G22A Inspection To inspect the drive belt check for frayed edges or tears and measure drive belt against the following speci fication If the belt shows excessive wear or damage replace the belt with a new one New 1 22 in 31
22. he battery recharged every 60 90 days to keep it fully charged The battery must be kept fully charged to avoid dam age NOTE AA SL Batteries like the one supplied with your car normally do not require you to check the water level inside the battery for the one year warranty period provided by the manufacturer 3 Clean the top of the battery with a solution of baking soda and water as necessary to remove corrosion CAUTION Do not allow cleaning solution to enter battery cells 9 2 SPECIFICATIONS GENERAL SPECIFICATIONS Dimensions Overall length 93 9 in 2385 mm Overall width 47 2 in 1200 mm Overall height steering height 46 8 in 1190 mm Height of floor 11 8 in 300 mm Wheelbase 64 3 in 1632 mm Tread Front 34 3 in 870 mm Rear 38 6 in 980 mm Min ground clearance 3 8 in 97 mm Weight Dry weight without battery 670 Ib 304 kg Performance Factory speed setting 12 mph 19 km h Maximum speed 15 mph 24 km h Minimum turning radius 114 2 in 2 9 m Seating capacity 2 persons Hill climbing ability 27 50 grade on pavement 1 0 1 G22A SPECIFICATIONS ENGINE Description Engine type Number of cylinders Displacement Bore x stroke Compression ratio Rated output Cooling system Starting system Ignition system Spark plug type Spark plug gap Lubrication system Engine oil type Engine oil capacity Oil change quantity TRANSMISSION Transmission T
23. he fuel system drain the applica ble part of the system to prevent fuel leaks e Avoid fire hazards and have appropriate fire protection equip ment available Before working on an electric golf car disable the car s electrical sys tem in accordance with the manu facturer s instructions e Use only properly insulated tools when working on electrically pow ered golf cars or around batteries Maintain all safety devices includ ing brakes steering mechanisms warning devices and governors in a safe operating condition Do not modify these safety devices as supplied by the manufacturer After each maintenance or repair the car must be driven by a quali fied trained and authorized per son in an area free of pedestrian traffic to ensure proper operation and adjustment G22A e Record all maintenance performed in a maintenance record log by date name of person performing maintenance and type of mainte nance Periodically inspect mainte nance log to ensure accurate and complete entries e Provide operator comment cards to assist in identifying non periodic maintenance needs for specific golf cars e Maintain in a legible condition all nameplates warnings and instruc tions provided by the manufacturer e If new nameplates warnings or instructions are needed contact your Yamaha dealer FUEL HANDLING STORAGE AND BATTERY CHARGING Take the following precautions to ensure maintenanc
24. igns to warn pedestrians of golf car traf fic and to warn golf car operators to drive slowly use caution and watch for pedestrians MAINTENANCE REQUIRED FOR GOLF CAR SAFETY Practice the following to help ensure the safety of golf car operators e Preventative Maintenance Per form all scheduled maintenance in accordance with manufacturer s recommendations to provide the golfing patron with a safe properly operating golf car e Personnel Allow only qualified trained and authorized personnel to inspect adjust and maintain golf cars 4 2 e Parts and Materials Use only replacement parts and materials recommended by the manufacturer Ventilation Properly ventilate all maintenance and storage areas in accordance with applicable fire codes and ordinances to avoid fire hazards Ventilation is required to remove flammable vapors and fumes from gasoline powered car storage areas Ventilation is also required to remove hydrogen gas from the car storage areas during the battery charging process G22A N GOLF COURSE SAFETY PROGRAM SAFETY PRECAUTIONS DURING MAINTENANCE When performing maintenance fol low all safety instructions contained in the manufacturer s operation and service manuals as well as the fol lowing safety procedures e Properly immobilize golf car before beginning any maintenance e Properly block chassis before working underneath golf car e Before disconnecting any part of t
25. on labels on the golf car before operat ing e Perform the pre operation checks found in Section 6 of this manual Only authorized people should drive the golf car from the driver s side only and only in designated areas e Do not allow more than two people to ride in the golf car This golf car is restricted to two occupants Do not operate the golf car while under the influence of alcohol or drugs their affect on vision and judgment make operating a golf car dangerous Do not operate the golf car on pub lic streets roads or highways Such use is prohibited by law and dan gerous Operation on public roads can result in collision with other vehicles WHILE OPERATING THE GOLF CAR e Keep your entire body inside the golf car remain seated and hold on when the car is in motion e Do not start the goli car until all occupants are seated 3 1 N OPERATOR SAFETY 3 2 e Keep your hands on the steering wheel and your eyes on the path ahead e Use extra care in congested areas or when backing up Always back up slowly and watch carefully e Avoid starting or stopping abruptly e Vary the speed of the golf car to match the terrain of the course e Avoid turning the steering wheel too sharply at higher speeds e Always drive slowly straight up or straight down slopes never at an angle e Do not run the engine indoors Exhaust gas is poisonous e Do not make any modification or ad
26. r Clean carburetor Consult Yamaha dealer Electrical System Spark plug dirty Clean carbon with carbon or or wipe spark wet plug dry Faulty ignition Consult system Yamaha dealer Foreign matter in fuel filter Clogged carburetor G22A STOPPING To stop the golf car gradually press down on the brake pedal Brake pedal When the car has come to a stop apply the parking brake pedal and turn the main switch to OFF Parking brake pedal CAUTION Do not hold the golf car on an incline with the accelerator use the brake 1 2 MAINTENANCE PERIODIC MAINTENANCE CHARTS Regular maintenance is required for the best performance and safe operation of your golf car 4 WARNING Be sure to turn off the main switch and apply the parking brake when you perform maintenance unless otherwise specified If the owner is not familiar with machine ser vicing this work should be done by a Yamaha dealer or other qualified mechanic FOR G22A C CHECK AND ADJUST R REPLACE S SERVICE CL CLEAN AND LUBRICATE L LUBRICATE 20 Rounds 125 rds 250 rds 500 rds 1000 rds 20 hours 125 hrs 250 hrs 500 hrs 1000 hrs Remarks 100 miles 600 mis 1200 mls 2500 5000mis 160 kms 1000 kms 2000 kms 4000 kms 8000 kms Every Every 6 Every Every Every month months year 2 years 4 years PRE Check engine oil c air cooling duct
27. ring the golf car CAUTION This message describes special precautions that must be taken to avoid damage to the golf car This message provides additional key information NOTE e Yamaha continually seeks ad vancements in product design and quality therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your golf car and this manual lf you have any questions concerning this manual please consult your Yamaha dealer e This manual should be considered a permanent part of your golf car and should remain with the car when resold WARNING Read and understand this manual completely before operating your golf car G22A CONTENTS WARRANTY IMPORTANT LABELS OPERATOR SAFETY MAINTENANCE SAFETY PROGRAM CONTROLS PRE OPERATION CHECKS OPERATION is MAINTENANCE STORAGE SPECIFICATIONS G22A WARRANTY YAMAHA MOTOR MANUFACTURING CORPORATION OF AMERICA LIMITED 3 YEAR GOLF CAR WARRANTY Yamaha Motor Manufacturing of America hereby war rants that any new Yamaha Car gas and electric models purchased from an authorized Yamaha dealer in the United States will be free from defects in material and workmanship for THREE years from date of pur chase subject
28. sseur ou niveau d huile qualified personnel du personnel qualiti JN3 K8291 10 Y 767 G22A 2 1 IMPORTANT LABELS 5 03 399 2 2 GOLF CAR SERIAL NUMBER The golf car serial number 1 is stamped in the location shown NOTE The first three digits of the serial num ber are for model identification the remaining digits are the unit produc tion number Keep a record of these numbers for reference when ordering parts from a Yamaha dealer The engine serial number 2 is affixed in the location shown 3 Engine Information IMPORTANT ENGINE INFORMATION ENGINE FAMILY REFER TO OWNER S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS YAMAHA DISPLACEMENT om VALVELASH mm Worte ua IGNITION TIMING amp IDLE MIXTURE NO OTHER ADJUSTMENTS NEEDED IDLE SPEED ATNOLOAD FUEL THIS ENGINE CERTIFIED TO OPERATE ON UNLEADED GASOLINE ENGINE OIL SAE 10W 30 D THIS ENGINE MEETS CALIFORNIA EMISSION REGULATIONS FOR OFF ROAD ENGINES THIS ENGINE CONFORMS U S EPA REGULATIONS FOR SMALL NONROAD ENGINES YAMAHA MOTOR CO LTD Y 851 G22A N OPERATOR SAFETY G22A Yamaha golf cars are designed to be simple to operate However be sure to observe the following BEFORE OPERATING THE GOLF CAR e Read this Owner s Operator s man ual and all safety and instructi
29. t the following warning be posted in a conspicuous location G22A Do Not Operate Golf Cars When Under The Influence Of Alcohol Or Drugs GOLF COURSE SAFETY SURVEY Perform safety surveys regularly to identify hazardous areas where golf cars should not be operated GOLF COURSE HAZARD PREVENTION The following golf course hazards must be made safe e Steep Grades Where steep grades exist restrict golf cars to designated golf car pathways where possible In addition identify steep grades with a suitable warn ing like Warning Steep Grade Descend Slowly With Foot On Brake e Sharp Turns Blind Corners Bridge Approaches Chain or rope off these potentially haz ardous areas or identify them with a suitable warning describing the nature of the hazard and the prop er precautions to be taken to avoid the hazard e Wet Areas Wet grass may cause a golf car to lose traction and may affect stability Chain or rope off wet areas or identify wet areas with a suitable warning 4 1 N GOLF COURSE SAFETY PROGRAM e Loose Terrain Loose terrain may cause a golf car to lose traction and may affect stability Repair loose terrain chain or rope off these areas or identify loose terrain with a suitable warning Golf Car and Pedestrian Interfer ence Reroute golf car traffic or pedestrian traffic in congested areas wherever possible to prevent accidents If it is impractical to reroute traffic erect warning s
30. te only when Do not start vehicle until all occupants are seated authorized and only e 5 Remain seated and hold on when in motion in designated areas Keep entire body inside vehicle v Drive slowly in turns Drive slowly straight up and down slopes kV Se parking brake before leaving vehicle Turn main switch to OFF and remove key when not in use Do not operate while under the influence of alcohol or drugs 7 OW Y 502 3 USE REGULAR UTILISER WARNING AVERTISSEMENT GASOLINE DE L ESSENCE Gasoline is wL essence ast ONLY SANS PLOMB extremely axtr memant inflammable Motor Oil Pour l huile du flammable m Garder tincellas flammas 1 n 1 Keep heat sparks chaleur loin du Regulremants moteur il faut and open flame r servoir a essence et si away from fuel des tuyaux carburant Z tank and fuel lines m Na pas ajouter d essence service SAE 10W 30 API m Do not add fuel pendant que le moteur service SE Qu SF while engine is est en marche ou quand le Maintain oil u Garder le niveau J running or hot mnteuccest chaud level between d huile entre les a Do not modify fuel Ne pas modifier le syst me dipstick MIN marques MIN et system Service d alimentation Toute pun MAX marks WA indiqu es should be performed r vision doit faite sur la jauge de by dealer or chez le fourni
31. to the stated limitations DURING THE PERIOD OF WARRANTY any autho rized Yamaha Golf Car Dealer will free of charge repair or replace at Yamaha s option any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the machine s war ranty period All parts replaced under warranty become property of Yamaha Motor Manufacturing Corporation of America GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Abnormal strain neglect or abuse including lack of proper maintenance and use contrary to the Owner s Operator s Manual instructions b Accident or collision damage c Installation of parts or accessories that are not original equipment d Fading rust or deterioration due to exposure ordinary wear and tear e Modifications or alteration that affects the cars condition operation performance or durability or which makes the car serve a purpose other than use as a two person golf course vehicle f Damage due to improper transportation g Acts of God ie lightning hail damage flooding fire etc SPECIFIC EXCLUSIONS The first year of warranty shall cover the entire car except for batteries battery chargers tires and rims which are warranted by their respective manufacturers Parts excluded from the sec ond year of warranty include the body parts seats mats bumper assembly bag
32. ype V belt width and outer line length V belt wear limit Governor Type Factory speed setting Differential reduction gear Differential type Lubricant capacity BATTERIES Battery 4 stroke Gasoline OHV Single 357 cm3 3 30 x 2 48 in 85 x 63 mm 8 1 1 11 4 hp 8 5 kw 3500 rpm Forced air cooled Starter TCI Magneto BPR2ES 0 028 0 031 in 0 7 0 8 mm Splash YAMALUBE 4 cycle oil or SAE 10W30 1 16 US qt 1 1 L 1100 cc 1 0 US qt 0 9 L 900 cc V belt automatic centrifugal engagement 1 22 x 39 76 in 31 x 1010 mm 1 06 in 27 mm Oil bath flyweight 12 mph 19 km h G22A Bevel gear SAE 90 gear oil 0 44 US qt 415 mL 415 cc BCI group 24 RC minimum 75 min CCA minimum 400A G22A 10 2 SPECIFICATIONS CHASSIS Steering system Type Steering angle L H Steering angle R H Brakes Brake system Type of brake Brake pedal freeplay linkage adjustment Brake cable end play Parking brake Type Release timing With pedal segment in second notch Bolt heads round parallel to arm Wheel Tire size Front Rear Rim size Tire pressure 10 3 Rack and Pinion 1 55 turn 1 55 turn Mechanical drum brake on each rear wheel with self adjusters Dual internal expanding shoe Leading trailing shoes self adjusting 20 25 mm 0 004 0 02 in 0 1 0 5 mm Foot type parking brake with automatic release 0 000 0 001 in 0 0 0 3 mm 18 x 8 50 8 00 4 PR
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